Gearbox Load and Life Simulation Software

Gear tooth surface fatigue (pitting) is common precursor failure mode that leads to excessive gear vibration, liberation of debris particles that damage ancillary components (e.g. bearings), and serves as crack initiation sites that lead to eventual catastrophic tooth failure. Current gearbox life estimation techniques commonly underplay the significance of gear tooth surface fatigue due to the complexity of the phenomenon involved. The Phase I program successfully demonstrated the feasibility of utilizing advanced modeling techniques to predict the onset and propagation of surface fatigue in gearing, including a rigorous analysis of misalignment, mixed-elastohydrodynamic lubrication, and damage accumulation in the material. Phase II will build on this success by applying these models to a complete gearbox, including a comprehensive graphical user interface for model construction and analysis control. Extensive verification of the models will ensure accuracy of the results. The completed software will provide analysts with a tool to predict the current damage state in helicopter gearboxes and evaluate remaining useful life for anticipated mission profiles.